Interlocking concrete decking



Aug. 1965 J. N. BURNS ETAL 3,197,933

INTERLOCKING CONCRETE DECKING Filed Dec. 18, 1961 3 Sheets-Sheet l 2 Fig.3 j 2 /8\ Q John N. Burns 30 32 I6 30 Jose M. Fernandez \la INVENTORS ..0... wWw M 3, 1955 J. N. BURNS ETAL 3,197,933

INTERLOCKING CONCRETE DECKING Filed D66. 18, 1961 3 Sheets-Sheet 2 John IV. Bums Jose M. Fernandez INVENTORS BY Q 3, 1955 J. N. BURNS ETAL 3,197,933

INTERLOCKING CONCRETE DECKING Filed Dec. 18, 1961 3 Sheets-Sheet 3 Fig. 8

John N. Burns Jose M. Fernandez INVENTORS BY 5%... :M

United States Patent 3,197,933 INTERLOCKING CONCRETE DECKING John N. Burns, 10730 th Ave. Gulf, and Jose M. Fernandez, R0. Box 2614, both of Marathon Shores, Fla.

Filed Dec. 18, 1961, Ser. No. 160,092 5 Claims. (Cl. 52-538) This invention comprises a novel and useful interlocking concrete decking and more particularly pertains to an interlocking decking construction whereby a plurality of monolithic precast and prestressed reinforced concrete channel members are securely connected together in side by side overlapping relation to form a continuous decking assembly.

It is the primary purpose of this invention to provide a concrete decking assembly having superior properties as to rigidity and strength, simplicity of construction, secure interlocking engagement between the various components of the assembly, together with superior rigidity, waterproof and heat insulating qualities.

A further object of the invention is to provide a concrete decking assembly which shall be capable of being assembled in any desired size by interlockingly connecting together a plurality of substantially identical monolithic precast and prestressed concrete channel elements.

A further object of the invention is to provide a concrete decking construction in accordance with the preceding objects in which the insulating means for the channel members serve the further functions of assisting in the interlocking action and in rigidifying the interconnection of the various component channel members of the assembly.

A still further object of the invention is to provide a concrete decking assembly in accordance with the foregoing objects in which there are provided improved readily applied but simple means for effectively anchoring selected ones of the channel members to a transversely extending support structure.

Yet another purpose of the invention is to provide a sectional concrete decking assembly in which a plurality of channel members disposed in upper and lower relatively staggered and inverted sets have their adjacent side walls interlockingly engaged with each other to establish a continuous decking assembly and a very secure interlocking engagement between the individual channel members.

Still another purpose of the invention is to provide a decking assembly in accordance with the above mentioned objects in which upper and lower sets of relatively inverted and staggered channel members have interlocked and engaging side walls together with a keying means therebetween to prevent displacement of the channel members from each other.

A still further object of the invention is to provide a prefabricated monolithic concrete sectional decking assembly in compliance with the hereinbefore set forth objects in which the channel members shall lend themselves to a variety of different configurations and cross sectional contours in consonance with the different and specific uses for which they are intended.

These together with other objects and advantages which ,will become subsequently apparent reside in the details structions.

3,197,933 Patented Aug. 3, 1965 the channel member of FIGURE 1 assembled into a portion of a concrete decking assembly;

FIGURE 3 is a detailed view taken upon an enlarged scale in vertical transverse section substantially upon the plane indicated by section line 33 of FIGURE 2 and showing interlocking joint connecting adjacent channel members of the assembly;

FIGURE 4 is a perspective view similar to FIGURE 1 but of a modified shape of channel member;

FIGURE 5 is a view in vertical transverse section showing the channel member of FIGURE 1 incorporated into a decking assembly;

FIGURE 6 is a view similar to FIGURE 5 but showing a further modification in which channel members of the type shown in FIGURES 1 and 4 are combined into a single decking assembly construction;

FIGURE 7 is a view in top plan, parts being broken away, and showing the manner in which the channel members are anchored to a support structure; and

FIGURE 8 is a detail view in vertical longitudinal section taken substantially upon the plane indicated by section line 88 of FIGURE 7 and showing further details of the anchoring of the decking assembly to a support structure.

Although FIGURES 1 and 4 show two different forms of a monolithic channel member forming a unit of the decking assemblies of FIGURES 2, 5 and 6, it will be readily appreciated that numerous other cross sectional contours and shapes can be provided for the channel members as may be preferred for different architectural con- However, inasmuch as the basic principles and features of these channel members are substantially identical regardless of their cross sectional shape, except for certain very minor differences set forth hereinafter,

a detailed description will be given first of the assembly shown in FIGURES 1-3 for an understanding of the basic principles of the invention.

As will be seen in FIGURE 2, a portion of the decking assembly 10 is illustrated consisting of upper and lower sets of channel members designated generally respectively at 12 and 14. These channel members may be of substantially identical construction in the interest of standardization except for one minor difference to be set forth hereinafter.

Each of these channel members consists of a web 16 having integral side walls 18 along the marginal edges thereof. The side walls are provided with a plurality of pretensioned wires or rods 20 embedded therein during the molding of the concrete body forming the channel member 12 or 14 and which serves to prestress the monolithic channel member. In the web portion 16 there are provided reinforcing means in the form of the usual wire screens or grills 22.

In the assembly 10 upper and lower sets of laterally spaced channel member 12 and 14 are disposed in relatively staggered overlying relation so that the depending side Walls 18 of the upper set 12 will be received within the adjacent side walls of the pair of adjacent lower channel members 14 to embracingly engage the same as shown in FIGURE 3. An interlocking action between the relatively engaging side walls of upper and lower channel members is provided. As illustrated in FIGURES 1-3 a number of such interlocking means is provided. Thus, on the adjacent inner surfaces of the side walls 18 of both upper and lower channel members 12 and 14 there are provided longitudinally extending grooves each indicated by the numeral 24. The grooves of the two adjacent side walls are complementary to and register with each other and when registered form a continuous longitudinally extending passage in the adjacent surfaces of the two side walls which may extend throughout any desired length of the channel members. A locking key in the form of a rigid rod-like member 26 is axially slidable into the complementary registering grooves 24 and thus prevents displacement of the two channel members from each other in directions which are perpendicular to their webs. This interlocking keying action may be regardless of whether the side walls have inclined cooperating surfaces or surfaces which are perpendicular to their webs.

As a further means to assist in maintaining the interlocking engagement of the engaged side walls the adjacent surface of the side walls as indicated at 28 may lie in a plane which is at an acute angle to the surface of the associated web 16, so as to produce a dovetailed or locking action between the cooperating channel members as shown clearly in FIGURE 3.

Still further interlocking means is provided by a layer of a lightweight thermally insulating cement as at 30 which is bonded to the inside surface of each of the webs.

referably this layer is applied while the concrete material of the channel members 12 and 14 are still wet although having initially set in their molds. The side edges of the layers 30 as indicated at 32 terminate in spaced relation to the adjacent side Walls 18 to provide a space therebetween which loosely receives the edge portions of the associated interengaged side walls of the adjacent channel member. This clearance is sufficient to permit insertion of the side legs thereinto, but to definitely limit lateral movement of the side walls away from each other. As will be apparent, the locking key 28 to some extent may be relied upon to take up some of this slack and thus secure a tighter engagement in this joint between the two channel members.

It will also be appreciated that in some instances it may be preferred to omit one or more of the locking key and groove constructions 24 and26, or the relatively inclined side wall surfaces 28, or the cement layer 30. However, one or more of these elements may be employed simultaneously with advantageous results, depending upon the degree of strength and security desired for the interlocking engagement of the members and the waterproof qualities of this joint.

In this particular construction it will be noted that in order for water to pass from the interior to the exterior of the decking, the water which will normally drain in the trough provided between two adjacent upper channel members 12 and upon the lower channel member 14 associated therewith would have to pass into the opening between the ends of the layer 30 and the side walls 18 of the adjacent upper members, then pass beneath the side walls 18, then upwardly between the surfaces 28 between the two engaged side walls, past the locking member 26, then over the top of the side walls 18 of the lower channel member and beneath the web of the upper channel member, and then downwardly through the space 32 between the side wall 18 of the lower channel member and the layer 30 of the upper channel member. This circuitous and tortuous path will greatly retard the flow of water therethrough thus materially enhancing the waterproof qualities of this interlocked joint.

' A further important feature of the invention and the chief difference between the constructions of the upper and lower channel members 12 and 14 is that the side walls 18 of the upper channel members 12 are of greater vertical'extent than are the corresponding side walls 18 of the lower channel members 14. As a result of this construction, as shown in somewhat exaggerated form as shown in FIGURE 3, the entire weight of the upper channel member rests upon the web 16 of the lower channel members by virtue of the bearing of the side walls 18 of the upper channel members upon this web. None of the load is therefore transmitted from the web 16 of the upper channel members 16 to the upper edge of the side walls 18 of the lower channel members. Inasmuch as it is intended that the lower channel members shall engage upon the support structure, it is obvious that the weight of the upper channel members is thus more effectively applied directly to the support structure with less possibility of the lateral forces being undesirably applied to the side walls of the channel members.

If desired, in some instances, various waterproof or other sealing materials may be additively applied between the contacting surfaces of this joint to further enhance the waterproofing quality thereof.

A further feature of the invention also resides in the fact that the exterior surfaces of the web 16 of both upper and lower channel members 12 and 14 may likewise have applied thereto a layer of a lightweight thermally insulating cement as indicated at 40. As a result of the cement layers 30 and 40 the decking has a very pronounced thermal insulating value.

In the decking assembly 10 of FIGURES 1-3 there is illustrated and described the construction of upper and lower channel members which have planar webs. However, it is possible to employ with the same principles of the invention webs of various curvatures and shapes other than planar. Thus, as shown in the construction of FIG- URES 4 and 5, a deck assembly indicated generally by the numeral 50 is provided consisting of upper and lower sets of channel members 52 and 54 respectively which are related to each other in exactly the same manner and are constructed in exactly the same manner as set forth in connection with the arrangement of FIGURES l-3. The sole difference between this form of the invention and that of FIGURES 1-3 is that the channel members 52 and 54 each have their web portions 56 of an arcuate configuration with the integral side walls 58 projecting therefrom. Moreover, the end surfaces 60 of these side walls lie in planes which are inclined to rather than being perpendicular to the planes of the side surfaces of the side walls so that when the relatively inverted channel members 52 and 54 are interengaged with each other as shown in FIGURE 5, the engagement of the surface 60 with the web 56 of the adjacent channel member will establish a firm abutting engagement where the upper member rests upon the lower member. As in the preceding form, however, it is preferred to provide a slight clearance between the web of the upper channel members and the adjacent upwardly extending side walls of the lower channel members for the reasons previously set forth. Inasmuch as the construction of the channel members in this arrangement and their functions are identical with those previously described a further description is thought to be unnecessary.

In the still further slightly modified arrangement of the deck assembly indicated generally by the. numeral 79 of FIGURE 6, a slightly modified construction of the channel members 52 is combined with the channel members 14 of the previously mentioned form. Here the upper channel members are of arcuate cross sectional contour as previously described in connection with the embodiments of FIGURES 4 and 5, while the lower channel members have planar surfaces to their webs as described in connection with FIGURES 1-3. Consequently, the side Walls 72 of the, channel members 70 are provided with plane lower surfaces 74 which are flush with and engage the webs 16 of the lower channel members 14 when the side surfaces of the side walls of the upper and lower channel members are in snug engagement as shown in FIGURE 6.

It will further be noted that the upper ends of the Side walls 18 of the lower channel member 14 has an arcuate surface 76 which is complementary to the curved internal surface of the web 56 of the upper channel members. Further, as in the preceding forms of the invention it is preferred to provide a slight clearance between the surfaces 76 and the webs 56 so that the entire load of the upper channel member will rest upon the web 16 of the bottom channel members by engagement of the surface 74 upon this web.

Inasmuch as the details of construction of the channel members in this form of deck assembly are identical to that previously described a further description is thought to be unnecessary.

It will be readily appreciated that different contours can be given to the webs of the channel members and to their side wall structures without departing from the principles of the invention as set forth herein and as claimed hereinafter.

Reference is now made to the arrangement shown in FIGURES 7 and 8 in conjunction with FIGURES 1-4 for an understanding of an anchoring arrangement by which the channel members are secured to a supporting structure which forms an important feature of this invention.

In FIGURES 7 and 8 the numeral 86 designates a support member which extends transversely of the plurality of channel members forming the various decking assemblies, the supporting member being preferably a precast monolithic concrete element. Supported by this support member is a decking assembly designated generally by the numeral 82 which may be of any of the types above mentioned or various other types as may be desired. For convenience of illustration, there has been shown the manner in which the decking assembly lid of FIG- URES 1-3 is appliedto the support memberdil. Accordingly, the same reference numerals have been employed for the elements of the decking assembly as were used in connection with the arrangement of FIGURES 1-3.

As shown in FIGURES 7 and 8, the upper set of channel members 12 overlies and engage with the lower set of channel members 14 in the manner previously described. The lower set of channel members is supported upon the support member either directly or by any suitable interposed structure as may be desired. Projecting upwardly from the support. member 80 and into the space between any or all of the upper channel members are one or more metallic reinforcing elements 84 which may conveniently comprise metal plates. These plates are spaced a sufficient distance from the side walls so as to permit lateral adjustment of the latter during the course of assembling of the construction. Further, the plates have their upper ends terminating well below the layer 349 of the upper channel member 12.

As will be noted fromFiGURES 14 each of the upper and lower channel members 10, 12, 52 and 54 are provided with openings or apertures 86 therethrough which expose the reinforcing means 22. These openings are of suiiicient size to permit the insertion therethrough of anchor means 88 which may conveniently comprise metal hooks or the like which when inserted through its openings may engage upon and be connected to the reinforcing means 22. The lower end of these anchor means project well into the space enclosed between the upper channel member and the associated side walls of the associated lower channel members.

The arrangement is such that a mass of cementitious material 90 may be inserted through the openings 86 and into the space to intimately bond with the support member 85), the members $4, and the concrete side walls 18 or 53, the insulating linings 30 and the anchor means as. This cementitious material will also fill up the opening 86. Thus selected ones or all of the upper channel members may be securely and intimately bonded to the support means and thus in turn will secure the lower channel members in space.

In some instances it will be appreciated that a similar anchoring arrangement may be provided for the open- I ings 86 in the lower channel members 14. In other instances, these openings may be omitted in the lower channel members with only the openings being employed in the upper channel members, while as previously set forth, selected ones only of the upper channel members may be utilized as the anchoring agent of the decking assembly.

The foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly all suitable modifications and equivalents may be resorted to, falling within the scope of the invention as claimed;

What is claimed as new is as follows:

'1. A concrete decking construction comprising a pinrality of monolithic, precast and prestressed reinforced concrete channel members, each member including an elongated web with marg nal side Walls, said members being disposed in upper and lower sets of laterally spaced members, the members of the upper set staggered and inverted and in overlying relation to those of the lower set, the side walls of each upper set member embracingly engaging in side-by-side relation the adjacent side walls of a pair of adjacent lower set members thereby providing a continuous decking, the side walls of each upper set member having a base portion resting upon the elongated webs of two adjacent lower set members and the side walls of the lower set being of less height than those of the upper set whereby the entire weight of the upper set members will be directly carried by the webs of the lower set members, a layer of lightweight thermally .insulating cement bonded tothe face of each web between its side walls, said layer terminating in spaced relation to said side walls and providing spaces therebetween receiving the side walls of the associate channel members of the other set, said layer retaining said engaging side Walls against lateral displacement.

2. The combination of claim 1 including an additional layer of lightweight thermally insulating cement bonded to the outside faces of said webs.

3. The combination of claim 1 including a support extending transversely of said plurality of members, at least one channel member of one of said sets having reinforcing means embedded in its web, anchor means connected to said reinforcing means and secured to said support.

4. The combination of claim 1 including a support extending transversely of said plurality of members, at least one channel member of one of said sets having reinforcing means embedded in its web, anchor means connected to said reinforcing means and secured to said support, said web having opening therethrough providing an entrance to the reinforcing means and the space between said web and support for the insertion of said anchor into said space and into engagement with said reinforcing means.

5. The combination of claim 1 including a concrete support member extending transversely of and supporting said members, at least one channel member of said upper set having reinforcing means embedded in its web, an anchor means connected to said reinforcing means and means securing said anchor means to said support member.

References Cited by the Examiner UNITED STATES PATENTS 211,944 2/79 Taylor 50 241 318,372 5/85 Crabbe 50-235 867,954 10/07 Davis 50-175 1,570,839 1/26 Joaquin 50-241 1,590,744 6/26 Hatch 50-220- 1,985,786 12/34 Kohlhass 58-368 2,129,369 9/38 Faber 50-363 2,137,009 11/38 StrOmberg 50-366 2,151,399 3/39 White 59-446 2,220,349 11/40 Plumb 56-464 2,675,695 4/54 Coff 50-366 (Qther references on foiiowing page) FOREIGN PATENTS Australia. France. France. France. Germany.

748,104 4/56 GratBritain.

' HENRY C. SUTHERLAND, Primary Examiner.

WILLIAM I. MUSHAKE, Examiner. 

1. A CONCRETE DECKING CONSTRUCTION COMPRISING A PLURALITY OF MONOLITHIC, PRECAST AND PRESTRESSED REINFORCED CONCRETE CHANNEL MEMBERS, EACH MEMBER INCLUDING AN ELONGATED WEB WITH MARGINAL SIDE WALLS, SAID MEMBERS BEING DISPOSED IN UPPER AND LOWER SETS OF LATERLALY SPACED MEMBERS, THE MEMBERS OF THE UPPER SET STAGGERED AND INVERTED AND IN OVERLYING RELATION TO THOSE OF THE LOWER SET, THE SIDE WALLS OF EACH UPPER SET MEMBER EMBRACINGLY ENGAGING IN SIDE-BY-SIDE RELATION THE ADJACENT SIDE WALLS OF A PAIR OF ADJACENT LOWER SET MEMBERS THEREBY PROVIDING A CONTINUOUS DECKING, THE SIDE WALLS OF EACH UPPER SET MEMBER HAVING A BASE PORTION RESTING UPON THE ELONGATED WEBS OF TWO ADJACENT LOWER SETS MEMBERS AND THE SIDE WALLS OF THE LOWER SET BEING OF LESS HEIGHT THAN THOSE OF THE UPPER SET WHEREBY THE ENTIRE WEIGHT OF THE UPPER SET MEMBERS WILL BE DIRECTLY CARRIED BY THE WEBS OF THE LOWER SET MEMBERS, A LAYER OF LIGHTWEIGHT THERMALLY INSULATING CEMENT BONDED TO THE FACE OF EACH WEB BETWEEN ITS SIDE WALLS, SAID LAYER TERMINATING IN SPACE RELATION TO SAID SIDE WALLS AND PROVIDING SPACES THEREBETWEEN RECEIVING THE SIDE WALLS OF THE ASSOCIATE CHANNEL MEMBERS OF THE OTHER SET, SAID LAYER RETAINING SAID ENGAGING SIDE WALLS AGAINSG LATERAL DISPLACEMENT. 